Method and apparatus for aligning sheet material

1. An apparatus for determining sheet material edges on a surface, comprising:

a sensor located adjacent to the sheet material and configured to detect an outer edge and a usable edge of the sheet material; and

a controller in communication with the sensor;

wherein the sensor comprises:

a first color optical sensor producing a first signal representing the usable edge; and

a second color optical sensor producing a second signal representing the outer edge;

wherein the controller comprises a processor, a memory, and a communications adapter;

wherein the controller controls dispensing and spreading of the sheet material for detection by the sensor; and

wherein the controller signals to a user a presence of the usable edge in the sheet material upon detection by the sensor.

2. The apparatus of claim 1 , further comprising an operator panel in communication with the controller.

3. The apparatus of claim 2 , wherein the operator panel comprises a touch screen interface.

4. The apparatus of claim 1 , further comprising backlighting of the sheet material, said first and second color optical sensors and said backlighting together permitting measurement of light attenuation.

5. The apparatus of claim 3 , wherein the controller determines one or more of material thickness, thickness variability, and pattern detection.

6. The apparatus of claim 1 , wherein said first color optical sensor and said second color optical sensor recognize color shifts within the sheet material.

7. The apparatus of claim 6 , wherein, upon recognition of said color shifts within the sheet material, said controller alerts a machine operator of a potential issue with said color shifts outside of acceptable parameters of a desired tolerance.

8. The apparatus of claim 1 , further comprising a cutter in communication with said first and second color sensors and said controller and configured for cutting the sheet material along the usable edge.

9. The apparatus of claim 1 , further comprising an obstacle sensor sensing impediments in the way of the sheet material upon dispensing and spreading.

10. The apparatus of claim 1 , further comprising a reflector on an opposing side of said sheet material from said first and second color optical sensors.

11. The apparatus of claim 1 , further comprising a light source on an opposing side of said sheet material from said first and second color optical sensors.

12. The apparatus of claim 1 , wherein the first and second color optical sensors further communicate instructions for aligning the usable edge of the sheet material to said controller.

13. A method of determining sheet material edges on a surface, comprising the steps of:

detecting, by a sensor located adjacent to the sheet material, an outer edge and a usable edge of the sheet material;

controlling, by a controller comprising a processor, a memory, and a communications adapter in communication with the sensor, dispensing and spreading of the sheet material for detection by the sensor; and

signaling, by the controller to a user, a presence of the usable edge in the sheet material upon detection by the sensor;

wherein the sensor comprises:

a first color optical sensor producing a first signal representing the usable edge; and

a second color optical sensor producing a second signal representing the outer edge.

14. The method of claim 13 , wherein the controller comprises the steps of:

initiating dispensing of a first layer of said sheet material;

ceasing dispensing of said first layer upon detection by said first and second color optical sensors of a proper orientation of the usable edge on the first layer of sheet material;

initiating dispensing of at least a second layer of the sheet material; and

aligning the usable edge of the first layer with a usable edge of at least the second layer.

15. The method of claim 13 , further comprising the step of cutting, by a cutter in communication with said first and second color optical sensors and said controller, the sheet material along with usable edge.

16. The method of claim 13 , further comprising the step of recognizing, by the first color optical sensor and said second color optical sensor, color shifts within the sheet material.

17. The method of claim 16 , further comprising the step of alerting, by the controller to a user upon recognition of said color shifts within the sheet material, a potential issue with said color shifts outside of acceptable parameters of a desired tolerance.